2012 Chevrolet Malibu Service & Repair Manual
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2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Transmission | Automatic Transmission - 6T40/6T45 |
Repair Instructions - Off Vehicle | Document ID: 2084528
Lift Plate and Holding Fixture Installation
Callout Component Name
1
DT-47811-A Transmission Lift Plate
Warning: Handle with care, the transmission assembly weighs over 83 Kg
(183 lbs). Bodily injury could occur if not handled properly.
Caution: Refer to Fastener Caution in the Preface section.
Tip
After installation of lift plate, raise the transmission with an overhead hoist.
Tighten
12 N·m (106 lb in)
2
J-46625 Transmission Holding Fixture
J-46625-10 Holding Fixture Adapter
Tip
Adjust mounting block on fixture to match bosses on case.
Tighten
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13 N·m (10 lb ft).
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2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Transmission | Automatic Transmission - 6T40/6T45 |
Repair Instructions - Off Vehicle | Document ID: 2084529
Torque Converter Removal
Callout Component Name
1
Lock Pin
Warning: Lock pin must be secured into the bench fixture to hold the transmission
and prevent bodily injury.
Tip
Ensure the J-3289-20 holding fixture is mounted to a bench that is properly
supported and will support the weight of the transmission assembly without tipping.
J-39890 holding fixture adapter and an engine stand can be used as an alternative
method for supporting the transmission assembly during repairs.
Special Tools
• J-3289-20 Holding Fixture
• J-39890 Transmission Holding Fixture Adapter
2 J-21366 Torque Converter Holding Strap
Torque Converter Assembly
Caution: Only install the lift assist handles until it stops. Do not tighten. Over
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3
tightening the lift assist handles can cause damage to the torque converter.
Tip
Failure to raise the torque converter straight up could damage the torque converter
clutch lip seal inside the torque converter clutch assembly.
Special Tools
J-46409 Torque Converter Lifting Handles
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2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Transmission | Automatic Transmission - 6T40/6T45 |
Repair Instructions - Off Vehicle | Document ID: 2084530
Control Valve Body Assembly Removal
Control Valve Body Cover Removal
Table 1: Control Valve Body Cover Removal
Table 2: Control Solenoid (With Body and TCM) Valve Assembly Removal
Table 3: Control Valve Body Assembly Removal
Control Valve Body Cover Removal
Callout Component Name
1 Control Valve Body Cover Bolts M6 x 30 (Qty: 13)
2 Control Valve Body Cover
3
Control Valve Body Gasket
Tip
Discard the seal. It is not reusable.
4
Control Valve Body Cover Wiring Connector Hole Seal
Caution: Support the control solenoid valve assembly around the connector when
removing the seal. Excessive pulling force can damage the internal electrical
connections.
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Control Solenoid (With Body and TCM) Valve Assembly Removal
Tip
Discard the seal. It is not reusable.
5 Shift Position Switch Connector
6 Output Speed Sensor Connector
7 Input Speed Sensor Connector
Control Solenoid (With Body and TCM) Valve Assembly Removal
Callout Component Name
1 Control Valve Body M5 x 40.5 (Qty: 3)
2 Control Valve Body Bolt M6 x 30 (Qty: 12)
3 Control Solenoid (with Body and TCM) Valve Assembly
4
Control Solenoid Valve Assembly Filter Plate
Caution: Use care when removing or installing the filter plate assembly. A broken
or missing retaining tab may not adequately secure the filter plate to the control
solenoid valve assembly, resulting in possible damage or contamination.
Tip
• Discard the filter plate. It is not reusable.
• Inspect the pressure switch seals for damage or contamination. Replace the
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Control Valve Body Assembly Removal
control solenoid valve assembly as necessary.
Control Valve Body Assembly Removal
Callout Component Name
1 Fluid Level Control Valve
2 Fluid Level Control Valve Gasket
3 Control Valve Body Bolt M6 x 60 (Qty: 9)
4 Control Valve Body Bolt M6 x 53 (Qty: 2)
5 Control Valve Body Assembly
6 Control Valve Body Spacer Plate Assembly
7 Manual Shaft Detent Spring Bolt M6 x 16 (Qty: 1)
8 Manual Shaft Detent Lever Spring Assembly
9
1-2-3-4 Clutch Fluid Passage Seal
Tip
Discard the seal. It is not reusable.
10
Low/Reverse Clutch Fluid Passage Seal
Tip
Discard the seal. It is not reusable.
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2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Transmission | Automatic Transmission - 6T40/6T45 |
Repair Instructions - Off Vehicle | Document ID: 1913056
Input and Output Speed Sensor Removal
Callout Component Name
1 A/Trans Output Speed Sensor Bolt M6 x 18 (Qty: 1)
2 A/Trans Output Speed Sensor Assembly
3 Input Speed Sensor Bolt M6 x 23 (Qty: 1)
4
Input Speed Sensor Assembly
Tip
Compress the locking tabs on the plug to release it from the case and to avoid
damaging the retainers.
5
Input Speed Sensor Assembly Seals (Qty: 3)
Tip
Discard the seals. They are not reusable.
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2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Transmission | Automatic Transmission - 6T40/6T45 |
Repair Instructions - Off Vehicle | Document ID: 1913059
Torque Converter Housing with Fluid Pump Assembly
Removal
Callout Component Name
1 Torque Converter and Differential Housing Bolts M8 x 30 (Qty: 15)
2 Torque Converter with Fluid Pump Housing Assembly
3
Torque Converter Housing Gasket
Tip
Discard the seal. It is not reusable.
4
Fluid Pump Seal Assembly
Tip
Discard the seal. It is not reusable.
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2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Transmission | Automatic Transmission - 6T40/6T45 |
Repair Instructions - Off Vehicle | Document ID: 1913062
Front Differential Carrier Assembly Removal
Callout Component Name
1 Front Differential Carrier Bearing Assembly
2 Differential Carrier Assembly
3 Final Drive Sun Gear
© 2010 General Motors Corporation. All rights reserved.
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What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
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Full Search Facility
Print one or all pages of your manual
$36.99
The 2012 Chevrolet Malibu Service & Repair Manual is a comprehensive guide that provides detailed instructions and information for servicing and repairing the Chevrolet Malibu. It includes step-by-step instructions, diagrams, illustrations, and specifications for various maintenance and repair tasks.
This manual is designed for the 2012 Chevrolet Malibu and is compatible with all trim levels and engine options available for this model year, including the LS, LT, or LTZ trim, and the 2.4L or 3.6L engine.
Key features of the 2012 Chevrolet Malibu Service & Repair Manual:
- Comprehensive instructions: Detailed procedures and step-by-step instructions for maintenance and repair tasks.
- Diagrams and illustrations: Visual aids to help understand procedures and components.
- Specifications: Detailed specifications for parts, components, and systems.
- Troubleshooting guides: Help in identifying and resolving common issues and problems.
- Maintenance schedules: Recommended intervals and procedures to keep your Malibu running smoothly.
- Compatibility: Works with all 2012 Chevrolet Malibu trim levels and engine options.
Whether you are a professional mechanic or a DIY enthusiast, the 2012 Chevrolet Malibu Service & Repair Manual is an essential tool for maintaining and repairing your vehicle. It provides a user-friendly interface and comprehensive content to keep your Malibu in top condition.
